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Detailing
Cut wire shots are manufactured by cutting wire into lengths equal to wire diameter (also called Wire pellets). If required, the particles can be conditioned (rounded) to remove the sharp corners that are produced during the cutting process. We have adopted strict quality control procedures in order to manufacture steel cut wire shots that comply with industry standards and norms.
Cut particles are an effective abrasive due to the sharp edges that are created during the cutting process. However, a normal cut shot is not a desirable shot peening media and the sharp edges, which are potentially damaging to fatigue life, must be removed in the conditioning process.
Conditioned steel cut wire shots are generally designed in various degrees of conditioning - normal conditioning that meets the shape requirements of SAE J441 specifications, and the less and more rounded special conditioning that fulfills the requirements of Aerospace specifications, like AMS 2431
Characteristics : - Good abrasion - improves work efficiency.
- Highly durable - reduces manufacturing time and cost.
- Stable peening effect because of uniform hardness and particle size.
- Low breakage and less dust contribute to a better environment (ISO14001).
- Variety of products available to match the material, hardness and purpose of the work piece.
Hardness Range :
Different hardness ranges are available with cut wire media, which depends on the type of application. Normally, the higher the media hardness, the lower will be the durability. However for shot peening applications, the used shot should be at least as hard as Almen strips or the part being peened, whichever is harder.
The common hardness ranges in carbon steel cut wire shot, include - blasting applications - HRC 45-50; shot peening high strength parts, like carburized gears and springs HRC 55-60; and Shot Peening softer parts, such as HRC 50-55.
Versatility :
Versatility is one of the most important aspects of steel cut wire shots. High in versatility, these can be made from various materials, such as stainless steel, carbon steel of various hardness levels, aluminium and zinc. Size of media can vary and is not limited to the standards.
Conditioning is done in Standard degrees, including - As-cut, normal, double and special. Some other degrees of conditioning can also be done. Various other hardness ranges can also be provided other than those discussed above.
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 Cut Wire Shot Sizes | Cut-wire Size (Inches) | Cut-wire Shot Size (mm) | Equivalent Cast Shot Size | | .012 | 0.30 | S-70 | | .017 | 0.45 | S-110 | | .020 / .023 | 0.50 / 0.60 | S-170 | | .028 | 0.70 | S-230 | | .032 / .035 | 0.80 / 0.90 | S-280 | | .035 / .041 | 0.90 / 1.00 | S-330 | | .041 / .047 | 1.00 / 1.20 | S-390 | | .054 | 1.40 | S-460 | | .062 | 1.60 | S-550 | | .080 | 2.00 | S-660 | | .090 | 2.30 | S-780 | |
Cut Wire Shot Chart | Material | SIZES | WIRE | ROCKWELL
HARDNESS
RANGE | VICKERS
HARDNESS
RANGE | | Steel | .012 inch - .062 inch
(0.30mm - 1.60mm) | Carbon Spring Wire 1070 Class I
High carbon 1070 Class II | 48 - 55 C
55 - 60 C | 446 - 595
595 - 697 | | Stainless Steel | .014 inch - .125 inch
(0.35mm - 3.2 mm) | Type 302/304 Spring Wire
| 48- 58 C
30 - 35 C | 446 - 653
302 - 345 | | Aluminum | .020 inch - .125 inch
(0.50mm - 3.2 mm) | Commercial Quality Pure Aluminium
Types 5053 - Full Hard
Types 1100-1345 - Full Hard | 50-70 B
30-40 B | N/A | | Zinc | .024 inch - .125 inch
(.61 mm - 3.2 mm) | Commercial Quality Pure Zinc | 20 - 30 B | N/A | |
Difference b/w Steel Shots & Cut Wire Shots | Cut Wire Steel Shots | Cast Steel Shots | | Finest quality raw material in exact compositions is used, which is free from any material defects or holes and porosity. | Low-grade raw material is used that make cause holes, porosity & shrinkage and make the shot fracture into small particles. | | Grain size is stabilized due to its drawing process. | Grain size is unstabilized. | | Being made out of same wire, all cut wire shots are identical. | Product is a mix of various spherical sizes. | | Uniform hardness | Large hardness variation | | Micro-structure is only Tempered Martensite | In Microstructure, carbides are always there. | | Low inventory required. | More inventory, more money and more storage required for same job. | | Cut Wire Shots only wear down. | Cast Steel Shots break into dust. | | Less consumption. | Consumption is high than Cut Wire Shots. | | Consistent superior performance | Poor consistency as a result of fast size deterioration. | | Operational life is 3-4 times more than Cast Steel Shots | Operational life is less. | | High purchase price. | Lower purchase price. | |
Vickers Rockwell Hardness and Conversion Table Vickers Hardness :
Vickers Hardness is a measure of the hardness of a material or cut wire steel shot, which is calculated from the size of an impression produced under load through a pyramid-shaped diamond indenter. Developed in the 1920s by engineers at Vickers, Ltd. (UK), the diamond pyramid hardness test is used to permit the establishment of a continuous scale of comparable numbers that reflect accurately the comprehensive range of hardness found in steels.
The indenter used in the Vickers test is a square-based pyramid the opposite sides of which meet at the apex at an angle of 136°. These diamonds are pressed into the surface of the material at loads that are available in range of up to approximately 120 kilograms-force, and the size of the impression (usually no more than 0.5 mm) is calculated with the aid of a calibrated microscope.
Vickers test is reliable method for measuring the hardness of metals and is also used on ceramic materials.
Rockwell Hardness :
The Rockwell Hardness test is a hardness measurement tool, which is based on the net increase in depth of impression as a load is implemented. The hardness numbers have no units and are generally given in the scales of R, L, M, E and K. The higher the number in each of the scales, the harder will be the material. The method was devised by Mr. Stanley P. Rockwel, who devised the test and original machines.
The technique is used to measure the hardness by pressing an indentor into the surface of steel with a specific load and then measuring how far the indentor can penetrate it. While there are several Rockwell tests, the most widely used is Rockwell B. Rockwell C, which are used on hard materials.
In the case the material is highly thin, lighter loads must be used. Resulting in Rockwell scales, like - 30T, 1ST, Rockwell 15-N and 30-N. There are conversion charts that provide for conversion from one method of hardness to another, but it is important to note that these conversion charts cannot exactly convert from one to another.
For Conversion Table Please Click Below Link:
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The Advantage of using Steel Cut wire Shot against Casted Steel Shot Cost Benefit analysis : Below an example is been taken, trying to explain the benefits on using Cut Wire shot :-
For Example :-
Cast steel shot : Per M/c usage of shots is 2000kg
By using Sun tech
Cut wire shot: Per M/c usage shall come down to 1000kg
PLUS there are other Benefits :-
- Machinery maintenance is low - Break-down are less, due to low DUST generation.
- Production cycle time reduced by 30% to 40%
- Time is saved
- The capacity of the blasting machine increases
- We save on Electricity
- We save Man-power (labour)
- Better results - finishing improves
- Reduce inventory space
On giving figure to above mentioned factors, we found that there is a saving of 25 -35% overall (depending on product to product). |
Cut Wire Shot Specifications | Shapes: | Description | Specification | | As-cut Normal Conditioned Double Conditioned Special Conditioned Spherical | Cylindrical with Edges Spherical | C W S
SAE J441
VDF 8001
AMS 2431
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We also make Cut Wire Shot as per customer specifications.
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